Belt management system and method

ABSTRACT

A belt management system of the present invention is formed by a management server ( 1 ) that manages belts that are used in a belt conveyor, a terminal ( 2 ) that is provided in a location where the belt conveyor is installed, and a data server ( 3 ) that is provided in a company that manufactures and sells belts, wherein the management server is provided with: a transceiver unit ( 10 ) that receives in time series belt remaining thickness data that shows the thickness of the belt and that is supplied from the terminal at each one of predetermined periods; and a belt lifespan prediction unit ( 11 ) that, by writing the belt remaining thickness data in the management database in time series, and reading from the management database the belt remaining thickness data that has been stored in time series, and dividing the difference between the predetermined periods by the usage amount of the belt at each of the predetermined periods, and determining a unit amount of change in the usage amount units, and subtracting from the most recent belt remaining thickness data a management threshold value which shows the thickness of the belt and which is to be used as an indicator for replacement, and dividing the result of this subtraction by the unit amount of change, determines a remaining lifespan that shows the future amount of use until the belt needs to be replaced.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of International Application No.PCT/JP2013/063672 filed May 16, 2013, claiming priority based onJapanese Patent Application No. 2012-123554, filed May 30, 2012, thecontents of all of which are incorporated herein by reference in theirentirety.

TECHNICAL FIELD

The present invention relates to a belt management system that managesthe belt of a belt conveyor, and to a method for the same.

Priority is claimed on Japanese Patent Application No. 2012-123554,filed May 30, 2012, the contents of which are incorporated herein byreference.

BACKGROUND ART

Conventionally, belt conveyors are used for the transporting of mineralssuch as coal and ore that have been mined on-site at a mine, or for thetransporting of industrial products in a factory.

As is shown in Patent document 1 (see below), for example, operationsare carried out to detect any deterioration or damage to the belt of thebelt conveyor that is transporting the minerals such as coal and ironore.

Lacerations (i.e., vertical tears) in the longitudinal direction aregenerated in the belt by the deterioration of the belt or by thedetection operation, and it can be inferred in advance that the beltwill become damaged and obstructions to the transporting of ore will begenerated, and processing such as repairs and the like can consequentlybe performed.

DOCUMENTS OF THE PRIOR ART Patent Documents

[Patent document 1] Japanese Unexamined Patent Application (JP-A) No.2009-12957

SUMMARY OF INVENTION Technical Problem

However, in Patent document 1, although it is possible to infer inadvance that damage to the belt will occur, it is not possible to knowdefinitively exactly when the belt should be replaced.

Namely, the extent of the current damage to the belt can be ascertained,and an operator determines whether or not the belt should be replaced bythe extent of the deterioration.

Because of this, the belt is replaced at a point that is determined bythe operator, and because it is unclear as to when a belt will need tobe replaced, it is necessary for a replacement belt to be keptconstantly in inventory.

Because of this, the fact that a replacement belt needs to be keptconstantly in inventory means that belts are being held in inventoryunnecessarily, and this leads to an increase in the running costs of thebelt conveyor.

Moreover, if the transported material that is being transported by thebelt conveyor changes, the type of belt conveyor used on that line alsochanges, and there are many instances of belts being held in inventoryfor no purpose.

The present invention was conceived in view of the above-describedcircumstances, and it is an object thereof to provide a belt managementsystem that makes clear when a belt needs to be replaced, and reducesthe running costs of a belt conveyor by managing the belts being held ininventory, and to also provide a method for the same.

Solution to Problem

A belt management system according to a first aspect of the presentinvention is a belt management system that is formed by a managementserver that manages belts that are used in a belt conveyor, a terminalthat is provided in a location where the belt conveyor is installed, anda data server that is provided in a company that manufactures and sellsbelts, wherein the management server is provided with: a transceiverunit that receives in time series from the terminal belt remainingthickness data that shows the thickness of the belt and that is suppliedfrom the terminal at each one of predetermined periods; and a beltlifespan prediction unit that, by writing the belt remaining thicknessdata in the management database in time series, and reading from themanagement database the belt remaining thickness data that has beenstored in time series, and dividing the differences between thepredetermined periods by the usage amount of the belt at each of thepredetermined periods, and determining a unit amount of change in theusage amount units, and subtracting from the most recent belt remainingthickness data a management threshold value which shows the thickness ofthe belt and which is to be used as an indicator for replacement, anddividing the result of this subtraction by the unit amount of change,determines a remaining lifespan that shows the future amount of useuntil the belt needs to be replaced.

In the belt management system according to a second aspect of thepresent invention, when the remaining lifespan drops below a usageamount in the predetermined period that has been set in advance, thebelt lifespan prediction unit according to the first aspect transmits analarm recommending that the belt be replaced to the terminal and thedata server.

In the belt management system according to a third aspect of the presentinvention, a measuring unit that measures the belt remaining thicknessdata is provided in the belt conveyor according to the first or secondaspects, and the terminal transmits to the management server the beltremaining thickness data that has been measured after each of thepredetermined periods by the measuring unit.

In the belt management system according to a fourth aspect of thepresent invention, the usage amount according to the first through thirdaspects is the weight of transport material that has been transported bythe belt conveyor, and the remaining lifespan shows the weight that canbe subsequently transported from the point in time when the most recentbelt remaining thickness data was measured.

In the belt management system according to a fifth aspect of the presentinvention, the usage amount according to the first through third aspectsis the period for which the belt conveyor transported the transportmaterial, and the remaining lifespan shows the period for whichtransport material can be subsequently transported from the point intime when the most recent belt remaining thickness data was measured.

In the belt management system according to a sixth aspect of the presentinvention, the management server according to the first through fifthaspects is further provided with: an expenditure database in which arewritten and stored in belt conveyor units for each different type ofbelt a total cost of ownership including at least the belt price,maintenance costs, and the electricity cost; and a total cost ofownership calculating unit that determines a total cost in usage amountunits by dividing a sum total of the belt price, the maintenance costs,and the electricity cost that has been stored in the expendituredatabase by the usage amount, and then associating this total cost inusage amount units with the corresponding belt of the belt conveyor andwriting and storing the result in the expenditure database.

In the belt management system according to a seventh aspect of thepresent invention, the management server according to the first throughsixth aspects is further provided with: an inventory database in whichan inventory quantity for each different type of belt at the locationwhere the belt conveyor is installed, and a management remainingquantity which shows the minimum inventory quantity of each differenttype of belt that is required in order to manage the belt conveyor arewritten and stored in advance; and a belt inventory management unitthat, when the inventory quantity drops below the management remainingquantity, recommends to the terminal and the data server that it isnecessary to buy new inventory.

In the belt management system according to an eighth aspect of thepresent invention, the management server according to the first throughseventh aspects is further provided with: a fault database that showsdetection threshold values that are set for each line and are used todetermined whether or not a fault has occurred; and a fault managementunit that compares detection values showing the state of a belt that aresupplied from the terminal with the detection threshold values, and whenthe result of this comparison indicates a fault in the belt, transmits anotification to the terminal and to the data server that shows that afault has occurred in the belt.

A belt management method according to a ninth aspect of the presentinvention is a belt management method that causes a belt managementsystem that is formed by a management server that manages belts that areused in a belt conveyor, a terminal that is provided in a location wherethe belt conveyor is installed, and a data server that is provided in acompany that manufactures and sells belts to operate, wherein the beltmanagement method includes: a transmitting and receiving step in whichbelt remaining thickness data that shows the thickness of the belt andthat is supplied from the terminal at each one of predetermined periodsis received in time series; and a belt lifespan prediction step inwhich, by writing the belt remaining thickness data in the managementdatabase in time series, and reading from the management database thebelt remaining thickness data that has been stored in time series, anddividing the differences between the predetermined periods by the usageamount of the belt at each one of the predetermined periods, anddetermining a unit amount of change in the usage amount units, andsubtracting from the most recent belt remaining thickness data amanagement threshold value which shows the thickness of the belt andwhich is to be used as an indicator for replacement, and dividing theresult of this subtraction by the unit amount of change, a remaininglifespan that shows the future amount of use until the belt needs to bereplaced is determined.

Effects of the Invention

According to this invention, because the usable lifespan is predictedfrom the amount of wear of a belt, the replacement time for the belt ismade clear, and by managing the inventory of belts to suit thisreplacement time, it is possible to avoid holding unnecessary inventory,and to thereby reduce the running costs of a belt conveyor.

Note that in the present invention, the term ‘plurality’ refers to anoptional number of at least two or more.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view showing an example of the structure of a beltmanagement system according to an embodiment of the present invention.

FIG. 2 is a block diagram showing an example of the structure of amanagement server in the belt management system shown in FIG. 1.

FIG. 3A is a view illustrating a calculation of the remaining lifespanof a belt by a belt lifespan prediction unit in the management serveraccording to an embodiment of the present invention.

FIG. 3B is a view illustrating a calculation of the remaining lifespanof a belt by a belt lifespan prediction unit in the management serveraccording to an embodiment of the present invention.

FIG. 3C is a view illustrating a calculation of the remaining lifespanof a belt by a belt lifespan prediction unit in the management serveraccording to an embodiment of the present invention.

FIG. 4A is a view showing the structures of a management table for eachline of a belt conveyor that is installed in a particular factory, andof a usage history table that shows the usage history of the belt ofeach line with both these tables being stored in a management databaseaccording to an embodiment of the present invention.

FIG. 4B is a view showing the structures of a management table for eachline of a belt conveyor that is installed in a particular factory, andof a usage history table that shows the usage history of the belt ofeach line with both these tables being stored in a management databaseaccording to an embodiment of the present invention.

FIG. 5 is a view showing a relationship between a transport amount andbelt minimum remaining thickness data in belt remaining thickness dataaccording to an embodiment of the present invention.

FIG. 6A is a view showing an example of the structure of expendituretables (i.e., an operational table and the usage history table that aredescribed below) that are written in advance in an expenditure databaseaccording to an embodiment of the present invention and stored therein.

FIG. 6B is a view showing an example of the structure of expendituretables (i.e., an operational table and the usage history table that aredescribed below) that are written in advance in an expenditure databaseaccording to an embodiment of the present invention and stored therein.

FIG. 7 is a view showing an example of the structure of an inventorytable that is written in advance in an inventory database according toan embodiment of the present invention and stored therein.

FIG. 8A is a view showing an example of the structure of a table that iswritten in advance in a fault database according to an embodiment of thepresent invention and stored therein.

FIG. 8B is a view showing an example of the structure of a table that iswritten in advance in a fault database according to an embodiment of thepresent invention and stored therein.

FIG. 9 is a view showing a detection object that is embedded in the beltof a belt conveyor according to an embodiment of the present invention,and is used to detect vertical tears which are one form of damage to abelt.

FIG. 10 is a side view of a belt conveyor that uses a belt that isprovided with the detection object shown in FIG. 9.

FIG. 11 is a side view of a belt conveyor apparatus on a line accordingto an embodiment of the present invention.

FIG. 12 is a partial vertical cross-sectional view of principal portionsthat make up the belt conveyor apparatus shown in FIG. 11.

DESCRIPTION OF EMBODIMENTS First Embodiment

Hereinafter, an embodiment of the present invention will be described indetail with reference made to the drawings. FIG. 1 is a view showing anexample of the structure of a belt management system according to afirst embodiment of this invention.

In FIG. 1, a management server 1 is connected to an informationcommunication network I that includes the Internet, and performsprocessing such as determining replacement times and managing theinventory and the like of belts (i.e., conveyor belts) of belt conveyorsthat are used in factories or in mineral mines and the like.

Terminals 2 are installed in locations corresponding to each line suchas in administrative buildings of the aforementioned factories andmineral mines, and these terminals 2 transmit and receive data betweenthemselves and the management server 1 and data servers 3 (describedbelow) via the information communication network I.

The data servers 3 are provided in companies that manufacture and sellbelts (i.e., manufacturing and sales corporations) for the beltconveyors that are used in factories and mineral mines and the like, andthese data servers 3 transmit and receive data between themselves andthe management server 1 and the terminals 2 via the informationcommunication network I.

Moreover, in the present embodiment, for example, the belt managementsystem enables the terminals 2, the data servers 3, and the managementserver 1 to work in cooperation with each other, and the managementserver 1 efficiently provides a cloud service for the terminals 2 andthe data servers 3. This cloud service is constructed as a PaaS(Platform as a Service) that provides a basic infrastructure forexecuting applications that manage the belt inventory including theremaining lifespan of the belts (described below). Here, the managementserver 1 may be formed by a single server, or may be formed by aplurality of servers that perform the functions of managing the belts incooperation with each other.

When an operator executes an application for the above-described beltmanagement system from a terminal 2, the operator connects to an onlineservice of the management server 1 from that terminal 2. Under thecontrol of the application started up by this online service, theterminal 2 then displays on a display screen, for example, an inputcolumn for an ID (identification) code and a password (i.e.,identification information identifying the terminal 2), and an imagerequesting that the operator input an ID code and password into thisinput column. Namely, the identification information identifying theterminals 2 is actually information identifying the factory or minewhere each line is located.

Once the operator has input the ID code and password into the inputcolumn, the terminal 2 transmits the input ID code and password to themanagement server 1 via the information communication network I.

The management server 1 authenticates the ID code and password suppliedfrom the terminal 2, and using the data from each table (i.e., tablesthat are written in advance in each of a management database 15, anexpenditure database 16, an inventory database 17, and a fault database18 and stored therein) that corresponds to this ID code and password,performs management for the belt of the belt conveyor of the line in thefactory or mine or the like that corresponds to the ID code andpassword.

Next, FIG. 2 is a block diagram showing an example of the structure ofthe management server 1 in the belt management system shown in FIG. 1.

In this drawing, the management server 1 is provided with a transceiverunit 10, a belt lifespan prediction unit 11, a total cost of ownershipcalculating unit 12, a belt inventory management unit 13, a faultmanagement unit 14, the management database 15, the expenditure database16, the inventory database 17, and the fault database 18.

The transceiver unit 10 transmits and receives various items of data(described below) and notification signals (i.e., alarms) between itselfand both the terminals 2 and the data servers 3 via the informationcommunication network I.

Hereinafter, operations of each of the above-described belt lifespanprediction unit 11, total cost of ownership calculating unit 12, beltinventory management unit 13, and fault management unit 14 will bedescribed.

[Belt Lifespan Prediction Unit 11]

The belt lifespan prediction unit 11 calculates a belt wear rate (i.e.,a unit amount of change using time for the units) from belt remainingthickness data that shows the thickness of the belt and is sent in atime series at a fixed cycle (i.e., at fixed periods) from the terminals2. Note that the belt remaining thickness data does not necessarily needto be sent at fixed periods, and may simply be sent after predeterminedperiods, for example, the intervals between when the terminals 2 sendthe remaining thickness data may be irregular such as every week, orevery three days or the like. This belt remaining thickness data is datato which identification information for each of the respective terminals2 is attached, and that is supplied from the terminals 2 as a beltreplacement index. The belt remaining thickness data may be either datathat has been measured by an operator and input into a terminal 2, ordata that, as is described below, is measured by a measuring device andis collected from the measurement device by the terminals 2 atmeasurement periods which are set in advance (at a fixed cycle, theseperiods are used for the usage amount units) and is then transmitted. Inthe present embodiment, the usage amount is the period for which thebelt was used or, as is described below, the amount of transportation oftransported articles.

The belt lifespan prediction unit 11 subtracts the current beltthickness data from a previously set management limit value, andcalculates the remaining usable period by dividing the differenceresulting from this subtraction by the wear rate. This is then output asthe remaining lifespan. Here, the management limit value is set as anumerical value showing that the possibility of damage increases as thethickness of the belt decreases, and an operator who is charged with themaintenance of the belt conveyor sets this numerical value in advancefor each line of a belt conveyor by considering the type of transportmaterial being transported and the type of belt being used and also bytaking their previous experience into account.

Next, FIGS. 3A, 3B, and 3C are views illustrating a calculation of aremaining lifespan performed by the belt lifespan prediction unit 11.FIG. 3A shows belt remaining thickness data for the transverse directionof the belt that is supplied periodically from the terminals 2. Here,the transverse direction of the belt refers to a direction on a surfaceof the belt of the belt conveyor on which transport material is placedthat is perpendicular to the transporting direction of the belt. In FIG.3A, the horizontal axis shows the position in the horizontal directionof the belt (for example, P0 is the right end, P4 is the center, and P8is the left end of the belt), while the vertical axis shows thethickness of the belt (i.e., the remaining thickness).

FIG. 3B is a view illustrating the data structure of the belt remainingthickness data which is a group of the transverse direction thicknessdata shown in FIG. 3A. As is shown in FIG. 3B, the belt remainingthickness data is a group of thickness data for each one of a pluralityof positions in the transverse direction of the belt, namely, for eachone of nine positions P0 through P8.

This belt remaining thickness data is also supplied at each period bythe terminals 2 for each one of a plurality of measurement positions inthe transporting direction, for example, for each one of positions Q1through Q7 that run in the transporting direction. These positions inthe transporting direction divide the overall length of the belt into aplurality (seven in FIG. 3B) of sections, and are provided in each ofthese divided length units.

FIG. 3C is a view that is used to determine from the belt remainingthickness data at each of the times t1, t2, t3 a straight line 1 thatshows the amount of change in the belt remaining thickness per unittime. In FIG. 3C, the horizontal axis shows time, while the verticalaxis shows the thickness of the belt. The slope of the straight line 1shows the wear rate. The broken line portions of the straight line 1 areextrapolated portions, and the time tT where the single-dot chain linereaches the management limit value is the time where it is predictedthat the belt will need to be replaced. The belt remaining thicknessdata used in FIG. 3C is the belt remaining thickness data where theremaining thickness is at the minimum (i.e., is the belt minimumremaining thickness data) in 60 measurement locations, i.e., in thepositions P0 through P8 of each one of the positions Q1 through Q7.

Next, FIGS. 4A and 4B are views showing the structures of a managementtable for each line of a belt conveyor that is installed in a particularfactory, and of a usage history table that shows the usage history ofthe belt of each line with both these tables being stored in amanagement database 15. The management table is provided so as tocorrespond to an ID code and a password, and cannot be accessed from aterminal 2 that has a different ID code and password. FIG. 4A is amanagement table for each line of a belt conveyor that is installed in aparticular factory, and management tables for each one of a plurality oflines, for example, for lines L1, L2, and L3 are written in advance intothe management table storage area of the management database 15 and arestored therein. Here, the management data includes the belt length, thebelt manufacturer, the belt part number, the material being transported,the belt thickness initial value, and the management limit value and thelike.

Namely, the belt length is the total length (in meters: m) of the beltbeing used in the belt conveyor of a line. The belt manufacturer is thename of the manufacturer (i.e., the company name) that manufactures andsells the belt being used in the belt conveyor of a line. The belt partnumber is the product number that shows the type of belt. The materialbeing transported is the type of material being transported on eachline. The belt thickness initial value shows the thickness of the beltwhen the belt conveyor was installed (i.e., the initial mountingthickness). As has already been described, the management limit valueshows the thickness of a belt that needs to be replaced from thestandpoint of product quality which is set based on the type oftransport material being transported and on the type of belt being usedand with previous experience being taken into account.

Here, the data for each of the belt length, the belt manufacturer, thebelt part number, the material being transported, the belt thicknessinitial value, and the management limit value are input in advance intothe terminals 2, and are written in advance into the management table ofthe management database 15 by the transceiver unit 10 and storedtherein.

FIG. 4B is a usage history table showing the usage history of the beltsof each line shown in FIG. 4A, and usage history tables for each one ofa plurality of lines, for example, for the lines L1 L2, and L3 arewritten in advance into the usage history table storage area of themanagement database 15 and are stored therein. Here, the usage historydata includes the installation date, the date of the last measurement,the elapsed number of days, the total transport amount, the thicknessdata, the wear rate, the remaining lifespan, the planned replacementdate, and the like.

From this graph, it can be clearly determined for how long a periodtransported material will be able to be transported henceforth from thecurrent time, and estimating the approximate remaining period that thebelt will be able to be used for from the current point in time can bedone easily, so that planning order placements for each belt can beachieved with a high level of accuracy.

Namely, the installation date shows the year, month, and date that thebelt of the belt conveyor of each line was replaced with a new belt. Thedate of the last measurement shows the year, month, and date when themost recent belt remaining thickness data was supplied. The elapsednumber of days shows the number of days that have elapsed from the mostrecent installation date until the current year, month, and date. Thetotal transport amount shows the total amount of material that has beentransported by the belt from the installation date until the lastelapsed number of days. The thickness data shows the most recent minimumthickness data for the belt (i.e., the belt minimum remaining thicknessdata). The wear rate is the speed at which the belt is becoming worn,and shows the amount of wear in units of days when the thickness data issubtracted from the belt thickness initial value, and the differenceresulting from this subtraction is divided by the difference in daysbetween the last measurement date and the installation date. Theremaining lifespan is the number of days from the current date until theplanned replacement date, and shows the number of days when themanagement limit value is subtracted from the thickness data, and thedifference resulting from this subtraction is divided by the wear rate,and the difference in days between the elapsed number of days and thelast measurement date is then subtracted from the result of the abovedivision. The planned replacement date is the planned date for the beltto be replaced, and shows the year, month, and date when the managementlimit value is subtracted from the thickness data, and the differenceresulting from this subtraction is divided by the wear rate, and theresult of this division is then added to the last measurement date.Here, each of the line name, the installation date, the last measurementdate (i.e., the date when the current belt remaining thickness data wassupplied), the total transport amount, and the thickness data (i.e., theprevious belt minimum remaining thickness data) are supplied from theterminals 2, and are written and stored in the usage history table inthe management database 15 by the transceiver unit 10.

Returning to FIG. 2, the belt lifespan prediction unit 11 predicts theremaining lifespan and planned replacement date for each line in thefactory or mine where each terminal 2 is installed.

The belt lifespan prediction unit 11 extracts the minimum thickness datafrom among the plurality of items of belt remaining thickness data, forexample, from the belt remaining thickness data for the positions Q1through Q7 that is transmitted at fixed periods from the terminals 2 viathe transceiver unit 10, and uses this as the belt minimum remainingthickness data. Here, each time the belt remaining thickness data istransmitted at these fixed periods, the belt lifespan prediction unit 11writes and stores the received date in the usage history table of themanagement database 15 as being the date of the last measurement.

The belt lifespan prediction unit 11 also extracts as the belt minimumremaining thickness data the minimum thickness data from among the beltremaining thickness data for the plurality of positions that wastransmitted in one period. The belt lifespan prediction unit 11 thendetermines the straight line 1, as is shown in FIG. 3C, and calculatesthe wear rate as being the slope of this straight line. Moreover, thebelt lifespan prediction unit 11 also writes and stores in the usagehistory table of the management database 15 the belt minimum remainingthickness data at the date of the last measurement as being thethickness data.

At this time, the belt lifespan prediction unit 11 reads the previousbelt minimum remaining thickness data from the usage history table inthe management database 15, and determines the wear rate as the slopebetween the current (i.e., the most recent) belt minimum remainingthickness data and the previous (i.e., the one immediately priorthereto) belt minimum remaining thickness data. Namely, the beltlifespan prediction unit 11 subtracts the current belt minimum remainingthickness data from the previous belt minimum remaining thickness data,and divides the difference resulting from this subtraction by themeasurement period time so as to determine the wear rate.

The belt lifespan prediction unit 11 then writes and stores thedetermined wear rate in the usage history table in the managementdatabase 15.

Moreover, it is also possible for the belt lifespan prediction unit 11to read the belt thickness initial value from the management table inthe management database 15, and to subtract the current belt minimumremaining thickness data from the read belt thickness initial value, andto then divide the difference resulting from this subtraction by theelapsed number of days that it has read from the usage history table inthe management database 15. At this time, the belt lifespan predictionunit 11 reads the installation date and the last measurement date fromthe usage history table in the management database 15, and subtracts theinstallation date from the last measurement date so as to derive theelapsed number of days. The belt lifespan prediction unit 11 then writesand stores the determined wear rate in the usage history table in themanagement database 15. The belt lifespan prediction unit 11 also writesthe current belt minimum remaining thickness data in the thickness datain the usage history table in the management database 15.

Moreover, the belt lifespan prediction unit 11 reads the managementlimit value from the management table in the management database 15, andreads the wear rate from the usage history table, and subtracts themanagement limit value from the most recent belt minimum remainingthickness data, and divides the difference resulting from thissubtraction by the wear rate so as to determine the remaining lifespan.

The belt lifespan prediction unit 11 then adds the remaining lifespan tothe last measurement date, and determines the date when the remaininglifespan will drop below the management limit value, namely, determinesthe planned replacement date. Here, the belt lifespan prediction unit 11writes and stores both the calculated remaining lifespan and plannedreplacement date in the usage history table in the management database15.

Here, when the calculated remaining lifespan drops below a fundamentalremaining lifespan that has been stored in advance in the managementdatabase 15, the belt lifespan prediction unit 11 sends notificationrecommending that the belt be replaced to the terminal 2 and the dataserver 3 via the transceiver unit 10 after having attached theretoinformation identifying the line (i.e., information showing which beltconveyor is being used in any of the locations, namely, the ID code andpassword, the line name, and the like).

Moreover, this fundamental remaining lifespan may be determined, forexample, by the belt lifespan prediction unit 11 multiplying the amountsof wear during one measurement period, namely, by multiplying the wearrate by the time of one period, and is then written in advance in themanagement database 15 by the belt lifespan prediction unit 11. Notethat the fundamental remaining lifespan may be calculated based on afixed period, or may be determined by multiplying the wear rate by apredetermined time that has been established in advance.

Next, FIG. 5 is a view showing a relationship between the transportamount and the belt minimum remaining thickness data in belt remainingthickness data. The slope of the straight line 1 in this graph shows theamount of wear in transport amount units. In this way, the remaininglifespan may be the determined using the transport amount in units ofpredetermined periods (i.e., the transport amount in a fixed period isused as the usage amount units). The remaining lifespan at this time isdetermined as a transport amount (i.e., a unit change amount which usesthe transport amount as units) which shows whether or not the beltminimum remaining thickness data has dropped below the management limitvalue from the amount of transport material that is to be subsequentlytransported. The transport amount MT shows the total weight of transportmaterial when the belt minimum remaining thickness data drops below themanagement limit value. From this graph, it can be clearly determinedhow much transport material will be able to be transported henceforthfrom the current time, and estimating the approximate remaining periodthat the belt will be able to be used for can be achieved easily fromthe amount of material that is planned to be transported, so thatplanning order placements for each belt can be achieved with a highlevel of accuracy.

Returning to FIG. 2, the belt lifespan prediction unit 11 subtracts themanagement limit value from the most recent belt minimum remainingthickness data, and by dividing the difference resulting from thissubtraction by an amount of wear that corresponds to the unit transportamount, the transport amount until the belt minimum remaining thicknessdata reaches the management limit value is determined and used as theremaining lifespan.

The belt lifespan prediction unit 11 then divides the total transportamount when the most recent belt remaining thickness data was obtainedby the elapsed number of days, and uses the result of this division asthe average transport amount, which is the amount of materialtransported per day.

The belt lifespan prediction unit 11 then divides the remaining lifespanserving as a transport amount by the average transport amount, and addsthe result of this division to the last measurement date. The result ofthis addition is then determined to be the planned replacement date.

[Total Cost of Ownership Calculating Unit 12]

The total cost of ownership calculating unit 12 writes and stores costdata that is supplied from the terminals 2 in the expenditure tables inthe expenditure database 16.

Next, FIGS. 6A and 6B are views showing examples of the structure ofexpenditure tables (i.e., an operation table and a usage history table(described below)) in the expenditure database 16. In the same way asthe management tables, the expenditure tables are provided so as tocorrespond to an ID code and a password, and cannot be accessed from aterminal 2 having a different ID code and password.

FIG. 6A shows the structure of an operation table of the expendituredatabase 16 which shows the belt of the belt conveyor that is used oneach line in a factory or mine, and also shows the costs of operationsof the belt conveyor. In FIG. 6A, the line name shows each line, thecompany name shows the manufacturer of the belt that is used on the beltconveyor of that line, the installation date shows the date when thebelt was installed on that belt conveyor, and the material cost showsthe cost of that belt. Furthermore, the endless operating costs show thecosts involved in the task of mounting the belt in an endless circle soas to form the belt conveyor on each line. The maintenance costs showthe costs incurred by maintenance such as repairs to the belt of thebelt conveyor. The electricity cost shows the cost of the electricityused to operate the belt conveyor.

Returning to FIG. 2, the total cost of ownership calculating unit 12divides (the belt purchase cost+the endless costs+the electricity) bythe period of use in, for example, years, and divides the result of thisdivision by the belt length, and uses the result of this division as aTOC (total cost (/years)) corresponding to the period of use. Inaddition, the total cost of ownership calculating unit 12 divides (thebelt purchase cost+the endless costs+the electricity) by the transportamount (in, for example, the number of tons), and uses the result ofthis division as a TOC (total cost (/tons)) corresponding to thetransport amount. The total cost of ownership calculating unit 12 thenwrites and stores the obtained TOC in the expenditure tables in theexpenditure database 16. Here, the belt purchase cost is the materialcost shown in FIGS. 6A and 6B.

Namely, the total cost (/years) shows the cost per year that is obtainedby dividing the total expenditure from the point when the belt wasinstalled up until the current time by the number of years that the belthas been used using the following formula. The total cost (/tons) showsthe cost by weight that is obtained by dividing the total expenditurefrom the point when the belt was installed up until the current time bythe total amount of material that has been transported (for example, inunits of tons) using the following formula. Moreover, in order tosimplify comparisons of belts between a plurality of belt conveyors, thetotal cost (/years) and the total cost (/tons) may also be divided bythe length of the belt in each belt conveyor.

FIG. 6B is an example of the structure of a usage history table of theexpenditure database 16 which shows the belt of the belt conveyor thatis used on each line in a factory or mine, and also shows thereplacement history of the belt conveyor. In FIG. 6B, the line nameshows each line, the installation period shows the period from when thebelt was installed until that belt was replaced, the company name showsthe manufacturer of the belt that is used on the belt conveyor of thatline, and the material cost shows the cost of that belt. The endlessoperating costs show the costs involved in the task of mounting the beltin an endless circle so as to form the belt conveyor on each line.

The maintenance costs show the costs incurred by maintenance such asrepairs to the belt of the belt conveyor. The electricity cost shows thecost of the electricity used to operate the belt conveyor. The totalcost (/years) shows the cost per year that is obtained by dividing thetotal expenditure from the point when the belt was installed up untilthe current time by the number of years that the belt has been usedusing the following formula. The total cost (/tons) shows the cost byweight that is obtained by dividing the total expenditure from the pointwhen the belt was installed up until the current time by the totalamount of material that has been transported (for example, in units oftons) using the following formula.

Returning to FIG. 2, the total cost of ownership calculating unit 12calculates the total cost (/years) and the total cost (/tons) using thefollowing formula based on the line name, the company name, theinstallation date, the material cost, the endless operation costs, themaintenance costs, the total amount of material transported, and theelectricity cost (i.e., based on cost data). The total cost of ownershipcalculating unit 12 then writes and stores the total cost (/years) andthe total cost (/tons) in the operation table and usage history table inthe expenditure database 16.

Moreover, in the history of the line 1 shown in FIG. 6B, theinstallation period X˜ is information for the belt of the belt conveyorcurrently being used. The installation period S˜X shows informationrelating to the belt of the belt conveyor that was used during theperiod immediately prior to the current period. As a result of this, theTCO (Total Cost of Ownership) which shows the total operating costsincluding the operations of the belt conveyor is made visible to theoperator of the terminal 2.

As a result of this, in the present embodiment, an operator is able toascertain for each type of belt being used on the belt conveyor not onlythe price of the belt, but also the TCO of the belt conveyor of eachline, and can thereby easily compare the cost performance of the beltsbeing used.

[Belt Inventory Management Unit 13]

The belt inventory management unit 13 writes and stores inventory datathat is supplied from the terminals 2 via the transceiver unit 10 in ainventory table in the inventory database 17. This inventory dataincludes the manufacturer, the part number, belt identificationinformation, remaining quantity (i.e., inventory quantity), the partnumber total remaining quantity, and the management remaining quantity.In the same way as the management tables, the inventory table isprovided so as to correspond to an ID code and a password, and cannot beaccessed from a terminal 2 having a different ID code and password.

Next, FIG. 7 is a view showing an example of the structure of theinventory table in the inventory database 17. In FIG. 7, themanufacturer is the name of the company that manufactures and sells thebelt, the part number is a number showing the product type of that belt,and the belt identification information is information identifying eachindividual belt in lot units of those belts, for example, in units ofthe rolls on which the belts are wound. The remaining quantity shows theinventory quantity (for example, in units of meters) as a remainingquantity of the belt of the lot indicated by that belt identificationinformation, and a remaining quantity of “FUL” shows that the product isunused and that, for example, the entire 1000 meters still remains. Forlots that have already been used, the remaining quantity (i.e., theinventory quantity) is shown as it is in meter units. The part numbertotal remaining quantity shows the entire remaining quantity of the sameproduct.

For example, there are two “FUL” and one 200 m for the product number B1of Company A, so that the part number total remaining quantity is 2200meters. The management remaining quantity shows the minimum requiredinventory quantity of a belt that past experience suggests will beneeded in order to deal with a fault occurring in the belt of a beltconveyor.

Returning to FIG. 2, the belt inventory management unit 13 writes theinventory data supplied via the transceiver unit 10 from the terminals 2in the inventory table of the inventory database 17, and calculates thepart number total remaining quantity. Here, the belt inventorymanagement unit 13 adds together all of the remaining quantities ofbelts having the same part number, and writes and stores the result ofthis addition as the part number total remaining quantity such that itcorresponds to the part number in the inventory table in the inventorydatabase 17.

Moreover, each time updated information concerning belt inventory datais supplied from a terminal 2, the belt inventory management unit 13extracts the part number from this inventory data. As is describedabove, the belt inventory management unit 13 then determines the partnumber total remaining quantity that corresponds to the extracted partnumber.

Next, the belt inventory management unit 13 reads the managementremaining quantity that corresponds to the part number, and compares itwith the newly determined part number total remaining quantity.

If as a result of this comparison, the part number total remainingquantity is found to have dropped below the management remainingquantity, the belt inventory management unit 13 attaches informationidentifying the line to a notification that includes the part number andalso includes contents recommending that a new order be placed, andtransmits this notification to the terminal 2 and to the data server 3of the manufacturer that manufactures and sells this belt.

Moreover, the above-described inventory table is categorized accordingto manufacturer, however, it is also possible to create tables for themanufacturer, part number, belt identification information, remainingquantity, part number total remaining quantity, and management remainingquantity for each belt conveyor line.

As a result of this, an operator in a factory or mine or the like isable to constantly verify the latest inventory situation, and is able toeasily create a timetable to show when a suitable quantity (i.e.,length) of belt should be ordered. As a consequence, proper inventorymanagement can be performed enabling a sufficient quantity to deal withany damages to a particular belt to be kept in stock without anysuperfluous inventory being held.

Moreover, the manufacturer who manufactures and sells the belt is ableto predict approximately when and in approximately what quantity a beltmay be ordered from each factory and mine, and is consequently able toestablish a manufacturing timetable. Accordingly, the manufacturer isable to prevent problems such as having to hold superfluous inventory,or not being able to respond instantly to an order.

The above-described belt identification information is written into anRFID (Radio Frequency IDentification) or into a barcode that areattached or adhered to the roll of each belt or to the packing materialthereof. An operator at the factory or mine reads belt identificationinformation for inventory articles at regular intervals using an RFID orbarcode reader. If a roll is unused, the description [FUL], or if theroll has been used, the actual remaining quantity is used as theinventory data with the manufacturer and part number being addedthereto. The operator then connects the reader to the terminal 2, andtransmits the inventory data from the terminal 2 to the managementserver 1.

[Fault Management Unit 14]

The fault management unit 14 determines whether or not a fault exists bycomparing detection data supplied via the transceiver unit 10 from theterminals 2 with a preset threshold value (i.e., a detection thresholdvalue (described below)). If it determines that a fault does exist, itwrites and stores the fault data in a fault table in the fault database18. This fault data includes the detection date, the line number, andthe detection position and the like. In the same way as the managementtables, the fault table is provided so as to correspond to an ID codeand a password, and cannot be accessed from a terminal 2 having adifferent ID code and password.

Next, FIGS. 8A and 8B are views showing examples of the structure oftables that are written in advance and stored in the fault database 18.FIG. 8A is a threshold value table showing detection threshold valuesthat are used to determine whether or not a fault such as a breakage hasoccurred, and that are set for each line. In FIG. 8A, the line number isthe number of a line (i.e., is information identifying the line) that isinstalled in the factory or mine or the like, while the detectionthreshold value is set for each line, and is compared with a detectionvalue that shows the state of the belt being used on the line and thatis transmitted at fixed periods.

FIG. 8B is a fault history table showing in a time series informationabout the line on which a fault is determined to have occurred. In FIG.8B, the detection date shows the year, month, and date on which the linefault was detected, the line number is the number of the line where thebelt fault was detected, the detection position shows the position wherethe belt fault was detected, and the index is an address showing an areawhere an image that shows the position where the belt fault occurred isstored.

Next, FIG. 9 is a view showing a detection object 117 that is embeddedin a belt 113 of a belt conveyor, and is used to detect vertical tearswhich are one form of damage to a belt.

The belt 113 is provided with a main rubber body 116 that extends in abelt longitudinal direction (i.e., the direction in which transportedmaterial is transported) L, and with a plurality of detection objects117 that are placed at intervals from each other in the beltlongitudinal direction L. The main rubber body 116 is formed, forexample, from a rubber material that is able to undergo sulfurvulcanization. For this rubber material it is possible to use, forexample, natural rubber (NR), isoprene rubber (IR), butadiene rubber(BR), styrene-butadiene copolymer rubber (SPR), and the like eitherindividually or in various combinations.

Moreover, a plurality of tension members (not shown) that are formedfrom steel cord or from organic fiber cord are arranged in a belttransverse direction H so as to extend lengthwise in the beltlongitudinal direction L. Examples of an organic fiber cord includenylon, polyester, and aramid. The plurality of tension members arearranged inside the main rubber body 116 so as to extend oversubstantially the entire area in the belt transverse direction H in acentral portion in a thickness direction of the main rubber body 116.

The detection objects 117 are embedded inside the main rubber body 116in a portion thereof that is located further to the rear surface side ofthe main rubber body 116 than the central portion in the thicknessdirection where the tension members are embedded. A toroidal circuit 120that has a coil portion 119 and has a toroidal shape in plan view whenthe belt 113 is viewed in the thickness direction is provided in eachdetection object 117. The toroidal circuit 120 extends in the belttransverse direction H between the two side edge portions of the mainrubber body 116, and in the example shown in the drawing, when seen inthe aforementioned plan view, the toroidal circuit 120 has a rectangularring shape that is elongated in the belt transverse direction H.

In the coil portion 119, a conductive wire 119 a is wound around a coilaxis, and in the example shown in the drawing, the conductive wire 119 ais wound around a plurality of times. The coil axis of the coil portion119 extends in the aforementioned thickness direction, and the coilportion 119 excites a magnetic field in this thickness direction uponbeing supplied with current. In the aforementioned plan view, the coilportion 119 is formed in a spiral shaped that is wound around so as tobecome gradually narrower in diameter as it moves from one end of theconductive wire 119 a to the other end thereof, and the spacing betweenconductive wires 119 a that are mutually adjacent in the radialdirection of the coil portion 119 remains the same.

Moreover, each coil portion 119 of the plurality of detection objects117 are arranged such that their positions in the belt transversedirection H are the same as each other. In the present embodiment,because each coil portion 119 is arranged in the same way on one sideedge portion out of the two side edge portions of the main rubber body116, the positions in the belt transverse direction H of each coilportion 119 are mutually the same as each other.

Moreover, in the present embodiment, an oscillating power generator 121that, when vibration is applied to it, generates power and supplies thispower to the coil portion 119 is provided in the toroidal circuit 120.

The oscillating power generator 121 is provided with an excitation coil122 that is electrically connected to the coil portion 119, a magneticbody 123 that is positioned coaxially with the excitation coil 122, anda housing case 124 in which the excitation coil 122 and the magneticbody 123 are housed.

The housing case 124 is formed in a rectangular parallelepiped shapewhose sides, when seen in plan view, extend in both the beltlongitudinal direction L and the belt transverse direction H.

The excitation coil 122 is formed as a result of a conductive wire 122 abeing wound around the coil axis and, in the example shown in thedrawing, the coil axis of the coil portion 119 extends in the belttransverse direction H. The excitation coil 122 is formed by winding theconductive wire 122 a a plurality of times such the diameter of eachwind is the same, but with the position of each wind being shifted inthe belt transverse direction H so that the overall shape of theexcitation coil 122 is formed in a circular cylinder that extends in thebelt transverse direction H.

Moreover, the two end portions of the conductive wire 122 a that formsthe excitation coil 122 are fixed respectively to portions of thehousing case 124 that are mutually opposite each other in the beltlongitudinal direction L.

The magnetic body 123 is disposed such that it is able to move in thebelt transverse direction H. When the magnetic body 123 moves in thebelt transverse direction H along the coil axis of the excitation coil122, excitation force is generated by electromagnetic induction in theexcitation coil 122. In the example shown in the drawing, the magneticbody 123 is formed in a rod shape, and is inserted inside the excitationcoil 122. The size in the belt transverse direction H of the magneticbody 123 is equivalent to the size in the belt transverse direction H ofthe excitation coil 122. Both end portions in the belt transversedirection H of the magnetic body 123 are connected separately to aninternal surface of the housing case 124 via elastic components 125 thatare able to deform elastically in the belt transverse direction H. Inthe example shown in the drawings, the elastic components 125 are formedby coil springs.

Moreover, each of the oscillating power generators 121 in the pluralityof detection objects 117 is arranged such that their positions in thebelt transverse direction H are mutually the same as each other. In thepresent embodiment, because all of the respective oscillating powergenerators 121 are located in common with each other on the other sideedge portion where the coil portion 119 is not provided out of the twoside edge portions of the main rubber body 116, the positions in thebelt transverse direction H of each oscillating power generator 121 aremutually the same as each other. In addition, the positions in the beltlongitudinal direction L of the oscillating power generators 121 are thesame as the positions in the belt longitudinal direction L of the coilportion 119.

A connecting conductive wire 126 that extends in a circumferentialdirection around the toroidal circuit 120 and connects together the coilportion 119 and the oscillating power generator 121 is provided in thetoroidal circuit 120. The connecting conductive wire 126 is arranged asa pair of connecting conductive wires so as to sandwich the coil portion119 and the oscillating power generator 121 from both sides in the beltlongitudinal direction L.

The connecting conductive wire 126 is provided with main conductivewires 126 a that extend in the belt transverse direction H and whose twoend portions are located on the respective side edge portions of themain rubber body 116, and with a pair of auxiliary conductive wires 126b that extend in the belt longitudinal direction L from the two endportions of the main conductive wires 126 a.

The end portions of the two end portions of the auxiliary conductivewires 126 b that are not connected to the main conductive wires 126 aare separately connected to an end portion of the conductive wire 119 athat forms the coil portion 119, or an end portion of the conductivewire 122 a that forms the excitation coil 122 of the oscillating powergenerator 121. In the example shown in the drawings, these end portionsare joined together as a single body, and the coil portion 119, theexcitation coil 122, and the connecting conductive wires 126 are formedas a single body. Moreover, of the auxiliary conductive wires 126 b ofthe conductive wires 126, the auxiliary conductive wire 126 b that isjoined to the other end of the conductive wire 119 a that forms the coilportion 119 is placed further to the rear surface side of the mainrubber body 116 in the aforementioned thickness direction than the coilportion 119 such that the auxiliary conductive wire 126 b does not comeinto contact with portions of the coil portion 119 other than theaforementioned other end thereof.

FIG. 10 is a side view of a belt conveyor 110 that uses the belt 113 inwhich the detection objects 117 shown in FIG. 9 are provided.

As is shown in FIG. 10, as detection portions 114 and 115, a firstdetection portion 114 that is located at a transporting start positionP1 that is adjacent to a hopper 130 on a drive pulley 111 side thereofis provided on the carrier side of the belt path along which the belt113 passes, while a second detection portion 115 that is located at areturn start position P2 is provided on the return side of the belt pathalong which the belt 113 passes. The first detection portion 114 ispositioned so as to be adjacent to the hopper 130 in the beltlongitudinal direction L, while the second detection portion 115 ispositioned so as to be adjacent to a shake-off means 131 in the belttransverse direction H.

The respective detection portions 114 and 115 are located on outer sidesof the center in the belt transverse direction H of the belt 113 suchthat they face the aforementioned edge portions on the one side of themain rubber body 116 on the rear surface side of the belt 113, and theydetect vertical cracks in the belt 113 by detecting a magnetic fieldthat is excited by the coil portion 119. The detection portions 114 and115 may include, for example, a detection coil (not shown) in which aninduction current is generated by the magnetic field excited by the coilportion 119, and a device that detects the current value of theinduction current generated in this detection coil and outputs it asdetection data together with the line name to the terminal 2.

Here, as is shown in FIG. 10, when the belt 113 is in operation, iftransport material is dropped from the hopper 130 resulting in externalforce being applied to the carrier side of the belt 113, vibration isimparted to the carrier side of the belt 113 as it passes thetransporting start position P1. Vibration is also imparted to the returnside of the belt 113 as it passes the return start position P2 due tothe shake-off means 131.

When the portions of the belt 113 where the toroidal circuits 120 arelocated travel past the two start positions P1 and P2 to which vibrationis being imparted, provided that the toroidal circuits 120 are notbroken, current flows through the coil portions 119 as a result of theoscillating power generators 121 generating power, resulting in amagnetic field being excited. If, on the other hand, a vertical crackhas formed in the belt 113 so that the toroidal circuit 120 is broken,the current does not flow to the coil portion 119, and no magnetic fieldis excited. Accordingly, it is possible to detect vertical cracks in thebelt 113 using the detection of the magnetic fields excited by the coilportions 119 by the respective detection portions 114 and 115 that arelocated at the two positions P1 and P2.

Here, by gradually changing the distance between the individualdetection objects 117 and other adjacent detection objects 117, thepoint where a vertical crack has occurred can be detected using thecycle of the current detected by the detection portions 114 and 115.Moreover, a mark is set on the belt 113 as the placement start positionof the above-described belt detection objects 117, and for example,magnets or the like are embedded in side portions of the belt 113 thatdo not become worn, and these marks are then detected by a magneticsensor enabling the terminal 2 to accumulate detection data in units ofrevolutions for the belt 113.

Next, using the output from the magnetic sensor, each time the beltcompletes one revolution the terminal 2 transmits to the managementserver 1 the detection data output by the detection portions 114 and 115that was sampled in a time series.

The fault management unit 14 compares the detection data supplied fromthe terminal 2, namely, the current values measured by the detectionportions 114 and 115 in sequence with detection threshold values (i.e.,current values) read from the threshold value table.

Here, the fault management unit 14 detects a current value that exceedsthe detection threshold current value as a peak value, and measures thecycle in which this peak value was detected, and determines thesituation to be normal when the cycle is becoming sequentially longer.In contrast, if the cycle in which the peak value is detected firstbecomes longer, then becomes shorter again than the cycle immediatelyprior, the fault management unit 14 determines that a current valueexceeding the detection threshold value has not been detected, namely,determines that the detection object 117 in that position is notdamaged. Damage to this detection object 117 shows a vertical crack inthe belt 113. Because of this, the fault management unit 14 detects thatdamage from a vertical crack in the belt 113 has occurred.

Next, because a fault has occurred in the belt 113, the fault managementunit 14 creates the same number of images of the position of thedetection objects 117 in sequence from the start mark as the number ofpeaks including the peak of the current that was shorter than the cycleimmediately prior, and writes and stores these in the fault database 18.

The fault management database 14 also writes and stores in the faulthistory table in the fault database 18 the supplied year, month, anddate, the line number (i.e., the line name), the detection position(i.e., the number in sequence of the detection object 117 from the startmark), and the address of the area where the image showing the positionof the detection object 117 on the belt 113 is stored.

The fault management unit 14 attaches information identifying the lineto a notification showing damage to the belt of that line, namely, anotification showing that a fault has occurred, and transmits thisnotification to the terminal 2 and to the data server 3 by email or thelike.

By doing this, an operator who is charged with maintaining the beltconveyor is able to confirm the occurrence of any faults, and is able torespond to these within a short period of time. Furthermore, because thecompany that manufactures and sells the belt is able to acquireinformation showing the type of belt in which the fault occurredirrespective of where the belt conveyor was installed, that company isable to make preparations to respond immediately when an order arrives.

Moreover, in order to detect a breakage in the steel cord of the belt113, it is also possible to photograph an x-ray image of the belt 113using an x-ray apparatus, and to detect the position of the breakage inthe steel cord by performing image processing on this x-ray image. Thebreakage position in this case can be specified from the position wherethe end portions of the belt are connected together in the beltconveyor, and from the transporting speed of the belt conveyor.

[Belt Remaining Thickness Data and Measurement of the Transport MaterialTransport Quantity]

FIG. 11 is a side view of a belt conveyor apparatus 210 on a lineaccording to the present embodiment. FIG. 12 is a partial verticalcross-sectional view of principal portions that make up the beltconveyor 210 shown in FIG. 11. As is shown in FIG. 11 and FIG. 12, thebelt conveyor apparatus 210 is provided with an endless belt-shaped belt211 that transports transport material Y, a wear amount measuring means(i.e., a revolution detecting means) 212 that measures an amount of wearof a surface 211 a of the belt 211 on which the transport material Y isloaded, a load height measuring means 213 that measures the load heightof the transport material Y that has been loaded onto the belt 211, anda calculation unit (i.e., a revolution number measuring means) 214 thatacquires separate measurement data from both the wear amount measuringmeans 212 and the load height measuring means 213. This calculation unit214 is provided in the terminal 2.

The belt 211 is entrained between a pair of pulleys 215 and 216 that areable to rotate around rotation shafts that extend in a horizontaldirection. In the example shown in the drawing, a drive pulley 215 andthe slave pulley 216 are provided as the pair of pulleys 215 and 216,and the rotation shaft of these two pulleys 215 and 216 are parallelwith each other and also extend in the belt transverse direction H.

Moreover, the carrier side of the belt 211 where the surface 211 a facesvertically upwards travels between the drive pulley 215 and the slavepulley 216 while being supported in a trough shape by a plurality ofbelt supporting means 217 that are lined up in the belt circumferentialdirection L. Each belt supporting means 217 is provided with a centerroller 218 that is able to rotate freely around a rotation shaft thatextends in the belt transverse direction H, and supports a centerportion in the belt transverse direction H of the belt 211, and with apair of side rollers 219 that are placed on both outer sides in the belttransverse direction H of the center roller 218 and that are able torotate freely around rotation shafts that slope diagonally relative tothe rotation shaft of the center roller 218, and that support mutuallyopposite side edge portions in the belt transverse direction H of thebelt 211.

The carrier side of the belt 211 transports the transport material Ythat has been loaded onto the belt 211 from the slave pulley 216 (i.e.,the one pulley) side towards the drive pulley 215 (i.e., the otherpulley) side. A hopper (not shown) that drops the transport material Yonto the belt 211 is provided above the carrier side of the belt 211,and the carrier side of the belt 211 transports the transport material Ythat has been dropped from the hopper to an unloading portion (notshown) that is provided on the drive pulley 215 side.

In the example shown in the drawings, the return side of the belt 211where the surface 211 a faces vertically downwards travels while beingin a completely flat state in the belt transverse direction H.

A first magnetic field generating means 220 and a second magnetic fieldgenerating means 221 that generate magnetic fields towards the surface211 a side of the belt 211 are separately provided in the belt 211. Inthe present embodiment, the first magnetic field generating means 220and the second magnetic field generating means 221 are placed such thatthe positions thereof in the belt circumferential direction L aredifferent from each other, while the positions thereof in the belttransverse direction H are the same as each other.

The polarities of the respective magnetic fields of the first magneticfield generating means 220 and the second magnetic field generatingmeans 221 are different from each other on the surface 211 a side of thebelt 211. In the present embodiment, the magnetic field generating means220 and 221 are each formed by a single rubber magnet that hassufficient flexibility to enable it to be deformed as it follows thebelt 211, and the respective magnetic fields of the rubber magnet usedto form the first magnetic field generating means 220 and the rubbermagnet used to form the second magnetic field generating means 221 havedifferent polarities on the surface 211 a side of the belt 211. Therubber magnets are formed by bond magnetic objects that are formed, forexample, by dispersing the magnetic powder of a permanent magnetmaterial in a rubber compound such that the rubber magnets aremagnetized in the thickness direction of the belt 211. Rare earthmagnets such as neodymium-iron-boron or samarium-iron-nitrogen magnets,arco magnets, and ferrite and the like can be employed for the magneticpowder.

The first magnetic field generating means 220 is embedded, for example,in the belt 211 such that it is exposed from the surface 211 a thereof,and the first magnetic field generating means 220 becomes worn at thesame rate as the surface 211 a of the belt 211 is worn. As the surface211 a of the belt 211 becomes worn, for example, the size of themagnetic field generated by the first magnetic field generating means220, the range in the belt transverse direction H of the magnetic fieldgenerated by the first magnetic field generating means 220, and therange in the belt circumferential direction L generated by the firstmagnetic field generating means 220 all change. Namely, this firstmagnetic field generating means 220 is located on the belt 211 so as tocorrespond to each of the measurement points shown in FIG. 3B and suchthat the measurement points are clearly distinct.

The wear amount measuring means 212 measures the wear amount using thebelt 211 at the time it was first put to use as a reference, and, in thepresent embodiment, is formed by magnetic sensors that measure as theamount of wear of the surface 211 a of the belt 211 the magnetic fieldof the first magnetic field generating means 220 that, as is describedabove, changes in accordance with the amount of wear of the surface 211a of the belt 211. For example, Gauss meters or loop coils or the likecan be employed as the magnetic sensors.

The wear amount measuring means 212 is positioned so as to face thesurface 211 a on the return side of the belt 211. It is also possible toprovide a transverse direction guide (not shown) that regulates movementin the belt transverse direction H of the belt 211 in a facing portionof the belt path along which the return side of the belt 211 passeswhere it faces the wear amount measuring means 212, and to provide athickness direction guide that supports the belt 211 from the rearsurface side thereof and that restricts the belt 211 from moving away inthe thickness direction of the belt 211 from the wear amount measuringmeans 212.

Moreover, in the present embodiment, the wear amount measuring means 212detects a start and a finish of one revolution of the belt 211. In theexample shown in the drawings, the wear amount measuring means 212detects the magnetic field of the second magnetic field generating means221 as the start and finish of one revolution of the belt 211, and whenit detects the end of one revolution of the belt 211, the start of thenext revolution of the belt 211 is detected.

The load height measuring means 213 measures the load height of thetransport material Y that has been loaded onto one portion of the belt211. In the present embodiment, the load height measuring means 213 islocated in a measurement portion of the belt path on the carrier side ofthe belt 211 and is positioned on the drive pulley 215 side of thehopper. The load height measuring means 213 measures the load height ofthe transport material Y which has been loaded onto the portion of thebelt 211 that passes this measurement portion.

Moreover, the load height measuring means 213 is located on the surface211 a side of the belt 211, and is formed by distance sensors thatmeasure the distance from the load height measuring means 213 to thetransport material Y by emitting, for example, light such as laser lightor the like, or ultrasonic waves, and then receiving a reflection ofthis light or ultrasonic waves, and use this distance as the load heightof the transport material Y.

In the present embodiment, the load height measuring means 213 islocated above the belt 211 and the belt supporting means 217, and emitslight or ultrasonic waves towards the transport material Y that has beenloaded onto the belt 211.

In the example shown in the drawings, the load height measuring means213 is held by a bracket 222 such that, when the transport material Yhas not been loaded onto the surface 211 a of the belt 211, it emitslight or ultrasonic waves onto the center in the belt transversedirection H of the surface 211 a of the belt 211. The load heightmeasuring means 213 is positioned on the outer side in the belttransverse direction H of the center portion in the belt transversedirection H of the belt 211, and emits light or ultrasonic wavesdiagonally downwards towards the inner side in the belt transversedirection H.

The distance from the load height measuring means 213 to the transportmaterial Y changes in accordance with the load height, namely, thisdistance becomes shorter as the load height of the transport material Ythat has been loaded onto the belt 211 becomes larger, and this distancebecomes longer as the load height becomes smaller.

Load amounts of the transport material Y per unit load height that havebeen determined in advance are stored in the calculation unit 214, andbased on the load amount of transport material Y per unit load height,and on measurement data acquired from the load height measuring means213, the calculation unit 214 is able to calculate the load amount oftransport material Y that has been loaded onto the portion of the belt211 that passes the measurement portion at those timings when themeasurement data is acquired.

Moreover, the calculation unit 214 also determines when the belt 211 isin operation and is not in operation. In the present embodiment, basedon detection data for the start and end of one revolution of the belt211 that the calculation unit 214 acquires from the wear amountmeasuring means 212, the calculation unit 214 determines that the belt211 is in operation if, after it detects the start of a revolution ofthe belt 211, it detects the end of that revolution within apredetermined revolution time that has been set in advance. If, on theother hand, the calculation unit 214 detects the start of a revolutionbut does not detect the end of that revolution before the aforementionedpredetermined revolution time has elapsed, then the calculation unit 214determines that the belt 211 is not in operation. For this predeterminedrevolution time, it is possible to use, for example, a time obtained byadding an extra time margin to the standard time that it takes the belt211 to complete one revolution.

Furthermore, the calculation unit 214 also measures the number ofrevolutions of the belt 211 from the time when the belt 211 was firstput to use. In the present embodiment, based on the detection data fromthe wear amount measuring means 212, the calculation unit 214 measuresthe number of revolutions by adding one revolution to the number ofrevolutions made by the belt 211 each time the belt 211 completes onerevolution.

Moreover, in the present embodiment, based on measurement data for theamount of wear of the belt 211 that it acquires from the wear amountmeasuring means 212, the calculation unit 214 calculates the remainingthickness of the belt 211. The remaining thickness of the belt 211(i.e., the belt thickness data in the belt remaining thickness data) iscalculated by subtracting the amount of wear of the belt 211 from thethickness of the belt 211 when it was first put to use (i.e., the beltthickness initial value) which has been stored in advance in thecalculation unit 214.

Next, an operation of the belt conveyor apparatus 210 will be described.

In the belt conveyor apparatus 210, when the belt 211 is made to travelby the drive pulley 215, the calculation unit 214 determines whether thebelt 211 is in operation or is not in operation, and also continuouslyacquires measurement data from the load height measuring means 213. Ofthe measurement data acquired from the load height measuring means 213,the data that is acquired while the belt 211 is determined to be inoperation is used to calculate the total amount of transport material Y(described below). When the belt 211 is determined to be not inoperation, the calculation unit 214 does not need to acquire measurementdata from the load height measuring means 213.

The calculation unit 214 also measures the number of revolutions of thebelt 211, and each time the belt 211 has revolved for a fixed number ofrevolutions such as, for example, 1000 revolutions, the calculation unit214 acquires measurement data from the wear amount measuring means 212and measures the amount of wear using the wear amount measuring means212.

In the present embodiment, when the amount of wear is measured by thewear amount measuring means 212, the calculation unit 214 calculates thetotal amount of transport material Y that has been transported by thebelt 211 up until the time when the wear amount was measured based onmeasurement data acquired from the load height measuring means 213 fromthe time when the belt 211 was first put to use until the time when thewear amount was measured.

At this time, based on a plurality of measurement data items acquiredfrom the load height measuring means 213 at different timings while thebelt 211 was in operation, and on the load amount of transport materialY per unit load height, the calculation unit 214 individually calculatesthe load amounts of transport material Y that was loaded onto the belt211 at the respective timings when each one of the plurality ofmeasurement data items was acquired up until the time when the wearamount was measured.

Thereafter, the calculation unit 214 adds these respective load amountstogether so as to derive the total amount of transport material Y.

As has been described above, according to the belt conveyor apparatus210 of the present embodiment, at the time when the wear amount wasmeasured by the wear amount measuring means 212, the calculation unit214 calculates the total amount of transport material Y that has beentransported by the belt 211 up until that time when the wear amount wasmeasured.

In addition, at each measurement cycle, the terminals 2 transmit to themanagement server 1 the belt remaining thickness data determined by thecalculation unit 214 as well as the amount of transport material Y thathas been transported from the previous cycle until the current cycle.

Note that it is also possible to record a program that achieves thefunctions of the management server 1 shown in FIG. 1 on acomputer-readable recording medium, and for the belt management of thebelt conveyor to be performed by causing a computer system to read andexecute the program recorded on this recording medium. Note that theterm ‘computer system’ used here includes both OS and hardware such asperipheral devices and the like.

Moreover, if a WWW system is being employed, then the term ‘computersystem’ may also include a homepage providing environment (or displayenvironment).

Moreover, the term computer readable recording medium′ also refers toportable media such as flexible disks, magneto-optical disks, ROM, andCD-ROM and the like, and storage devices such as hard disks and the likethat are built into a computer system. Furthermore, ‘computer readablerecording medium’ includes devices that dynamically hold programs for ashort time such as communication lines when the program is beingtransmitted via a network such as the Internet or via a communicationcircuit such as a telephone line, and also includes devices that hold aprogram for a fixed time such as the internal volatile memory in acomputer system which forms the server or client in this case. Moreover,the program may be one that performs a portion of the above functions,or may be one that performs the above functions in combination with aprogram that is already recorded on a computer system.

An embodiment of this invention has been described in detail above withreference made to the drawings, however, the specific structure of thisinvention is not limited to this embodiment and various designmodifications and the like may be made thereto insofar as they do notdepart from the spirit or scope of this invention.

INDUSTRIAL APPLICABILITY

There is provided a belt management system and a method for the samethat make clear when a belt needs to be replaced, and reduce the runningcosts of a belt conveyor by managing the belts being held in inventory.

DESCRIPTION OF REFERENCE SIGNS

-   1 . . . Management server-   2 . . . Terminals-   3 . . . Data servers-   10 . . . Transceiver unit-   11 . . . Belt lifespan prediction unit-   12 . . . Total cost of ownership calculating unit-   13 . . . Belt inventory management unit-   14 . . . Fault management unit-   15 . . . Management database-   16 . . . Expenditure database-   17 . . . Inventory database-   18 . . . Fault database-   I . . . Information communication network

The invention claimed is:
 1. A belt management system that is formed bya management server that manages belts that are used in a belt conveyor,a terminal that is provided in a location where the belt conveyor isinstalled, and a data server that is provided in a company thatmanufactures and sells belts, wherein the management server is providedwith: a transceiver unit that receives in time series belt remainingthickness data that shows the thickness of the belt and that is suppliedfrom the terminal at each one of predetermined periods; a belt lifespanprediction unit that, by writing the belt remaining thickness data inthe management database in time series, and reading from the managementdatabase the belt remaining thickness data that has been stored in timeseries, and dividing the difference between the predetermined periods bythe usage amount of the belt at each of the predetermined periods, anddetermining a unit amount of change in the usage amount units, andsubtracting from the most recent belt remaining thickness data amanagement threshold value which shows the thickness of the belt, anddividing the result of this subtraction by the unit amount of change,determines a remaining lifespan that shows the future amount of useuntil the belt needs to be replaced; an expenditure database in which atotal cost of ownership is written and stored, in belt conveyor units,for each different type of belt, the total cost of ownership includingat least belt price, maintenance costs, and electricity cost; and atotal cost of ownership calculating unit that determines a total cost inusage amount units by dividing a sum total of the belt price, themaintenance costs, and the electricity cost that has been stored in theexpenditure database by the usage amount, and associating the total costin usage amount units with the corresponding belt of the belt conveyorand writing and storing the results in the expenditure database, whereina measuring device that measures the belt remaining thickness data isprovided in the belt conveyer, wherein the belt remaining thickness datais either data that has been measured and input into the terminal, ordata that is measured by the measuring device and is collected from themeasurement device by the terminal.
 2. The belt management systemaccording to claim 1, wherein, when the remaining lifespan drops below ausage amount in the predetermined period that has been set in advance,the belt lifespan prediction unit transmits an alarm recommending thatthe belt be replaced to the terminal and the data server.
 3. The beltmanagement system according to claim 1, wherein the terminal transmitsto the management server the belt remaining thickness data that has beenmeasured after each of the predetermined periods by the measuring unit.4. The belt management system according to claim 1, wherein the usageamount is the weight of transport material that has been transported bythe belt conveyor, and the remaining lifespan shows the weight that canbe subsequently transported from the point in time when the most recentbelt remaining thickness data was measured.
 5. The belt managementsystem according to claim 1, wherein the usage amount is the period forwhich the belt conveyor transported the transport material, and theremaining lifespan shows the period for which transport material can besubsequently transported from the point in time when the most recentbelt remaining thickness data was measured.
 6. The belt managementsystem according to claim 1, wherein the management server is furtherprovided with: an inventory database in which an inventory quantity foreach different type of belt at the location where the belt conveyor isinstalled, and a management remaining quantity which shows the minimuminventory quantity of each different type of belt that is required inorder to manage the belt conveyor are written and stored in advance; anda belt inventory management unit that, when the inventory quantity dropsbelow the management remaining quantity, recommends to the terminal andthe data server that it is necessary to buy new inventory.
 7. The beltmanagement system according to claim 1, wherein the management server isfurther provided with: a fault database that shows detection thresholdvalues that are set for each line and are used to determined whether ornot a fault has occurred; and a fault management unit that comparesdetection values showing the state of a belt that are supplied from theterminal with the detection threshold values, and when the result ofthis comparison indicates a fault in the belt, transmits a notificationto the terminal and to the data server that shows that a fault hasoccurred in the belt.
 8. A belt management method that causes a beltmanagement system that is formed by a management server that managesbelts that are used in a belt conveyor, a terminal that is provided in alocation where the belt conveyor is installed, and a data server that isprovided in a company that manufactures and sells belts to operate,wherein the belt management method includes: a computer systemimplementing the steps of: a receiving step in which belt remainingthickness data that shows the thickness of the belt and that is suppliedfrom the terminal is received in time series at each one ofpredetermined periods; a belt lifespan prediction step in which, bywriting the belt remaining thickness data in the management database intime series, and reading from the management database the belt remainingthickness data that has been stored in time series, and dividing thedifference between the predetermined periods by the usage amount of thebelt at each of the predetermined periods, and determining a unit amountof change in the usage amount units, and subtracting from the mostrecent belt remaining thickness data a management threshold value whichshows the thickness of the belt, and dividing the result of thissubtraction by the unit amount of change, a remaining lifespan thatshows the future amount of use until the belt needs to be replaced isdetermined; a recording step wherein a total cost of ownership iswritten and stored in an expenditure database, in belt conveyor units,for each different type of belt, the total cost of ownership includingat least belt price, maintenance costs, and electricity cost; and acalculating step wherein a total cost of ownership calculating unitdetermines a total cost in usage amount units by dividing a sum total ofthe belt price, the maintenance costs, and the electricity cost that hasbeen stored in the expenditure database by the usage amount, andassociating the total cost in usage amount units with the correspondingbelt of the belt conveyor and writing and storing the results in theexpenditure database, wherein a measuring device that measures the beltremaining thickness data is provided in the belt conveyor, wherein thebelt remaining thickness data is either data that has been measured andinput into the terminal, or data that is measured by the measuringdevice and is collected from the measurement device by the terminal. 9.A belt management method in which data is exchanged between a terminalthat is provided at a location where a belt conveyor is installed and amanagement server that manages the belts used on the belt conveyor,wherein the belt management method includes: a computer systemimplementing the steps of: a transmitting step in which belt remainingthickness data that shows the thickness of the belt is transmitted bythe terminal in time series to the management server after predeterminedperiods; a receiving step in which, when the remaining lifespandetermined by the management server that shows the future amount of useof the belt until it needs to be replaced drops below a usage amount inthe predetermined period that has been set in advance, an alarmrecommending that the belt be replaced is received by the terminal fromthe management server; a recording step wherein a total cost ofownership is written and stored in an expenditure database, in beltconveyor units, for each different type of belt, the total cost ofownership including at least belt price, maintenance costs, andelectricity cost; and a calculating step wherein a total cost ofownership calculating unit determines a total cost in usage amount unitsby dividing a sum total of the belt price, the maintenance costs, andthe electricity cost that has been stored in the expenditure database bythe usage amount, and associating the total cost in usage amount unitswith the corresponding belt of the belt conveyor and writing and storingthe results in the expenditure database, wherein a measuring device thatmeasures the belt remaining thickness data is provided in the beltconveyor, wherein the belt remaining thickness data is either data thathas been measured and input into the terminal, or data that is measuredby the measuring device and is collected from the measurement device bythe terminal.
 10. The belt management method according to claim 9,wherein the belt remaining thickness data that has been measured aftereach of the predetermined periods by the measuring unit is transmittedfrom the terminal to the management server.
 11. The belt managementmethod according to claim 9, wherein an inventory quantity for eachdifferent type of belt at the location where the belt conveyor isinstalled is transmitted by the terminal, and when the inventoryquantity drops below a predetermined management remaining quantity,notification from the management server is received by the terminalrecommending to it that it is necessary to buy new inventory.
 12. Thebelt management method according to claim 9, wherein detection valuesthat show the state of the belt are transmitted by the terminal to themanagement server, and when the detection values are compared with apreset detection threshold value and, as a result, indicate that thereis a fault in the belt, notification showing that a fault has occurredin the belt is received by the terminal from the management server.